Weldable stud



July 25, 1961 m up FIG.3

FIG. 2

United States Patent 1 2,993,982 WEL'DABL'E STUD Robert L. Glover, P.0. Box 207, Poland, Ohio Filed Oct. 9, 1959, Ser. No. 845,463 3 Claims. (Cl. 219-99) The invention relates to weldable studs which are adapted to be electrically welded to a plate, beam or other metal part.

An object of the invention is the provision of a weldable stud having an integral center core upon which the electric arc is ignited.

Another object of the invention is the provision of a weldable stud having a cavity at the end thereof and covered by a cap, the cap and the cavity forming a chamber for flux, the outer peripheral edge of said cap being unsupported.

Another object of the invention is the provision of a stub shaft extending through a central opening in the cap, wherein the end surface of the stub shaft is provided with a cupped recess thereby forming an annular brim at the end of the stub shaft to facilitate the ready ignition of the electric arc.

Another object of the invention is the provision of a stud having an outer flange and a center core defining a cavity therebetween for flux, the cross-sectional area of the flange being substantially the same as the cross-sectional area of the center core.

Another object of the invention is the provision of flux means comprising granulated aluminum and sponge iron mixed in amounts of approximately 50 percent by volume of aluminum and approximately 50 percent by volume of sponge iron.

Other objects and a fuller understanding of the invention may be had by referring to the following description and claims taken in accordance with the accompanying drawings, in which:

FIGURE 1 shows a side elevational view of a stud having an upper weldable end portion adapted to be pro cessed in accordance with my invention, the stud shown in FIGURE 1 being drawn to substantially full scale;

FIGURE 2 is a cross-sectional view of the weldable end portion of the stud which is drawn to double scale, and showing the first step of providing an annular recess in the end thereof;

FIGURE 3 is a view similar to FIGURE 2 and shows in addition thereto the step of providing a stub shaft at the end of the center core, this representing the second step;

' IGURE 4 is a view similar to FIGURE 3 but shows the recess provided with flux means, this representing the third step;

FIGURE 5 is a view similar to FIGURE 4 but shows a cap mounted to the end of the weldable stud portion and enclosing the flux, this representing the fourth step;

FIGURE 6 is a view similar to FIGURE 5 and shows the weldable end of the stud completely assembled, this representing the fifth and final step; and

FIGURE 7 is a side view of the finished stud shown in FIGURE 6.

With reference to FIGURE 1, the stud is indicated by the reference character 10 and may have a head 11 as shown, or instead of the head it may be provided with threads or other means. The upper end of the stud is designated as the weldable end portion and is indicated by the reference character 12. The first step in the process of manufacturing the weldable end portion of the stud comprises the machining of an annular cavity 19 in the end thereof. This machining produces an integral flange 13 and an integral center core 16. The integral flange 13 has an inside surface 14 and an outside surface 15. The

2,993,982 Patented July 25, 1961 "ice center core 16 has an outside surface 17. Bottom surface means 18 extend between the inside surface 14 of the flange 13 and the outside surface 17 of the core 16. The inside surface 14 of the flange 13, the outside surface 17 of the core 16 and the bottom surface means 18 form the cavity 19. The bottom surface means 18 and the outside surface 17 of the core 16 meet each other and define an inner annular corner 20 of the cavity 19. The bottom surface means 18 and the inside surface 14 of the flange 13 meet each other and define an outer annular corner 21 of the cavity. The center core 16 has an end surface 22 and an integral shaft 23 extending axially from the end surface 22. The shaft 23 has an outside surface 24 which meets with the end surface 22 of the core and defines an annular corner 25 whereby the end surface 22 of the core 16 constitutes an annular shoulder. The end surface 22 of the core and the outside surface 17 of the core meet each other and define an annular edge 26.

A cap 27 covers the cavity 19 and defines with the cavity a chamber for holding flux indicated by the reference character 32. The cap 27 has an outer peripheral edge surface 28 fitting within and spaced from the inside surface 14 of the flange. The outer peripheral edge surface 28 of the cap 27 is unsupported. The cap has an outside and inside surface with an opening extending therethrough into which the stub shaft 23 projects. The inside surface of the cap has a marginal peripheral inner portion 29 surrounding the opening and resting against the end surface or shoulder 22 of the core. The outside surface of the cap 27 has a marginal peripheral outer portion 30. The flange has an in-bent portion 31 with the inside surface 14 thereof overlapping the marginal peripheral outer portion 30 of the outside surface of the cap and holds the marginal peripheral inner portion 29 of the inside surface of the cap 27 against the end surface or shoulder 22 of the core. The flux 32 is confined by the cap within the cavity 19. In FIGURE 6, the stub shaft 23 has a cupped end surface 33 which substantially meets with the outside surface 24 thereof and defines an annular brim 34. The end surface of the shaft is cupped by a press operation which is performed in the same press movement that the in-bent flange is formed. The brim 34 aids in the ready ignition of the electrical arc. The annular brim 34 at the end of the stub shaft 23 constitutes the most remote part of the stud and extends in an axial direction beyond the outside surface 15 of the in-bent portion of the flange. The flux material comprises granulated aluminum and sponge iron mixed in amounts of approximately 50 percent by volume of aluminum and substantially 50 percent by volume of sponge iron. A typical analysis of the sponge iron may be as follows:

The sponge iron in combination with the aluminum makes a highly eflicient flux.

It is to be noted that the weldable end portion of the stud is processed to have a plurality of annular corners and edges. It appears that these annular corners and edges materially aid in the arcing situation to produce a good weld. The outer peripheral edge surface 28 of the cap is unsupported to aid in compacting the flux within the cavity 19. The cross-sectional area of the flange 13 and the cross-sectional area of the center core 16 are substantially equal to give substantially equal distribution of the arc.

Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from thespirit and the scope of the invention as hereinafter claimed.

What is claimed is:

l. A stud having a weldable end portion comprising an integral outer annular flange having an outside and inside surface, an integral center core having an outside surface disposed inwardly from and opposite the inside surface of said flange, bottom surface means extending between the inside surface of said flange and the outside surface of said core, said inside surface of said flange, said outside surface of said core and said bottom surface means forming a cavity, said bottom surface means and said outside surface of said core meeting each other and defining an inner annular corner of said cavity, said bottom surface means and said inside surface means of said flange meeting each other and defining an outer annular corner of said cavity, said center core having an end surface and an integral shaft extending axially from said end surface, said shaft having an outside surface, said outside surface of said shaft meeting with said end surface of said core and defining an annular corner whereby said end surface of said core constitutes an annular shoulder, said end surface of said core and said outside surface of said core meeting each other and defining an annular edge, a cap covering said cavity and defining therewith a chamber, said cap having an outer peripheral edge surface fitting within and spaced from the inside surface of said flange, said cap having an outside and an inside surface with an opening extending therethrough into which said shaft projects, said inside surface of said cap having a marginal peripheral inner portion surrounding said openin and fitting against said annular shoulder, said outside surface of said cap having a marginal peripheral outer portion, said flange having an in-bent portion with the inside surface thereof overlapping said marginal peripheral outer portion of the outside surface of said cap and holding said marginal peripheral inner portion of the inside surface of said cap against said annular shoulder, flux means in said cavity, said outer peripheral edge of said cap being unsupported with said in-bent portion of said flange pressing said cap against said flux means, said flux means spacing said inside surface of said cap from said bottom surface means, said shaft having a cupped end surface substantially meeting with the outside surface thereof and defining an annular brim at the end of said shaft, said annular brim at the end of said shaft being the most remote part of said stud and extending in an axial direction beyond the outside sfirface of the in-bent portion of said flange, said flux comprising granulated aluminum and sponge iron mixed in amounts of approximately per cent by volume of aluminum and'of approximately 50 percent by volume of sponge iron.

2. A stud having a weldable end portion comprising an integral outer annular flange having an outside and inside surface, an integral center core having an outside surface disposed inwardly from and opposite the inside surface of said flange, cavity means having bottom surface means between said flange and said core, said cavity means having wall means including the inside surface of said flange and the outside surface of said core, said center core having an end surface and an integral shaft extending axially from said end surface, said shaft having an outside surface, said outside surface of said shaft meeting \m'th said end 4 surface of said core and defining an annular shoulder, a cap covering said cavity means and defining therewith a chamber, said cap having an outer peripheral edge surface fitting within and spaced from the inside surface of said flange, said cap having an outside and an inside surface with an opening extending therethrough into which said shaft projects, said inside surface of said cap having a marginal peripheral inner portion surrounding said open. ing and fitting against said annular shoulder, said outside surface of said cap having a marginal peripheral outer portion, said flange having an in-bent portion with the inside surface thereof overlapping said marginal peripheral outer portion of the outside surface of said cap and holding said marginal peripheral inner portion of the inside surface of said cap against said annular shoulder, flux means in said cavity, said outer peripheral edge of said cap being unsupported with said in-bent portion of said flange pressing said cap against said flux means, said flux means spacing said inside surface of said cap from said bottom surface means, said shaft having a cupped end surface substantially meeting with the outside surface thereof and defining an annular brim at the end of said shaft, said annular brim at the end of said shaft being the most remote part of said stud and extending in an axial direction beyond the outside surface of the in-bent portion of said flange.

3. A stud having a weldable end portion comprising an integral outer annular flange having an outside and inside surface, an integral center core having an outside surface disposed inwardly from and opposite the inside surface of said flange, cavity means having bottom surface means between said flange and said core, said cavity means having wall means including the inside surface of said flange and the outside surface of said core, said center core having an end surface and an integral shaft extending axially from said end surface, said shaft having an outside surface, said outside surface of said shaft meeting with said end surface of said core and defining an annular shoulder, a cap covering said cavity means and defining therewith a chamber, said cap having an outer peripheral edge surface fitting within the inside surface of said flange, said cap having an outside and an inside surface with an opening extending therethrough into which said shaft projects, said inside surface of said cap having a marginal peripheral inner portion surrounding said opening and facing said annular shoulder, said outside surface of said cap having a marginal peripheral outer portion, said flange having an in-bent portion with the inside surface thereof overlapping said marginal peripheral outer portion of the outside surface of said cap and with said marginal peripheral inner portion of the inside surface of said cap facing said annular shoulder, flux means in said cavity, said outer peripheral edge of said cap being unsupported with said in-bent portion of said flange pressing said cap against said flux means, said flux means spacing said inside surface of said cap from said bottom surface means, said shaft having an end surface constituting the most remote part of said stud and extending in an axial direction beyond the outside surface of the in-bent portion of said flange.

References Cited in the file of this patent UNITED STATES PATENTS 2,421,184 Candy May 27, 1947 2,506,747 Smith May 9, 1950 2,760,797 Woodling Aug. 28, 1956 2,878,363 Shoup Mar. 17, 1959 

